Method of assembling a vehicle door

ABSTRACT

A vehicle door is assembled by immobilizing a cable drum with a wedge and then coupling the wedged drum to a drive member. A cable is wound onto the drum either before or after the positioning of the wedge. A drive member is then coupled to the wedged drum. After coupling, the drive member is fixed to the vehicle door. The window guide structure can also be inserted between the inner panel and an outer panel of the vehicle door. The wedge can be removed from the window guide structure, or alternately, the wedge can be fixed to the window guide structure. Alternately, the method further includes the steps of placing the cable in deflection pulleys before the steps of positioning the wedge and winding the cable. The drive member is pivotally mounted to the inner panel about an axis offset relative to the rotational axis of the drum, and the cable is tensioned by pivoting the drive member about the offset axis. The drive member is then fixed to the inner panel of the vehicle door. Essentially, a pre-assembled intermediate window drive is created that facilitates mounting to a vehicle door.

[0001] This application claims priority to French patent application FR 02 03 372 filed on Mar. 19, 2002.

BACKGROUND OF THE INVENTION

[0002] The invention relates generally to a method of assembling a vehicle door by immobilizing a cable drum with a wedge and then coupling the wedged drum to a drive member.

[0003] In a prior art method of assembling a vehicle door, a vehicle door frame is first secured to a fixture that retains the door frame in a secured position. A motorized double-lift drive member is then fixed to the retained door frame. Cables encased in plastics sheaths are then connected to the fixed drive member. A window is then mounted on runs connected to the cables. The assembly is then slid into and fixed to the vehicle door. This prior art method of assembling a vehicle door has been used in the Audi A4.

[0004] There are several drawbacks to the prior art method of assembling a vehicle door. For one, the drive member is located in a zone of the vehicle door partially exposed to moisture. Thus, expensive watertight connectors have been required. Additionally, corrosion-induced wear of the cables can occur, particularly if moisture enters the plastic sheaths. Finally, the plastic sheaths themselves reduce the drive efficiency of the drive member and add to the expense of the vehicle door.

[0005] Hence, there is a need in the art for an improved method of assembling a vehicle door that is less expensive and overcomes the drawbacks of the prior art.

SUMMARY OF THE INVENTION

[0006] The present invention relates to a method of assembling a vehicle door by immobilizing a cable drum with a wedge and then coupling the wedged drum to a drive member.

[0007] The vehicle door assembled by the method of the present invention includes a window guide structure and a cable drum. The window guide structure includes a guide frame having a guide slot. A wedge is positioned between the guide frame of the window guide structure and the drum, fixing the drum on the vehicle door structure. The drum is fixed in the longitudinal direction and vertical direction of the window. The wedge can also allow deflection of the drum a direction transverse to the vehicle door. A cable is wound onto the drum either before or after the wedge is positioned between the window guide frame and the drum.

[0008] Essentially, the invention to this point provides a pre-assembled window drive including the window guide structure, the drum, the wedge, the cable, etc. This pre-assembled structure is then taken and mounted to a vehicle door.

[0009] A drive member is then coupled to the wedged drum. After coupling, the drive member is then fixed to an inner panel of the vehicle door. Alternately, the window guide structure is inserted between the inner panel and an outer panel of the vehicle door, and then the drive member is fixed to the inner panel. After the drive member is fixed to the inner panel of the vehicle door, the wedge can be removed or fixed to the window guide structure to form a part of the drum housing.

[0010] Alternately, the drive member is a motorized reducer, and the method further includes the steps of placing the cable in deflection pulleys of the window guide structure before the steps of positioning the wedge and winding the cable on the drum. During the step of fixing the drive member to the inner panel, the motorized reducer is pivotally mounted to the inner panel about an axis that is staggered relative to the rotational axis of the drum. The cable is then tensioned by pivoting the motorized reducer about the staggered axis. The motorized reducer is fixed to the inner panel of the vehicle door.

[0011] These and other features of the present invention will be best understood from the following specification and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The various features and advantages of the invention will become apparent to those skilled in the art from the following detailed description of the currently preferred embodiment. The drawing that accompany the detailed description can be briefly described as follows:

[0013]FIG. 1 shows a front view of a window guide structure of a vehicle door;

[0014]FIG. 2 shows a cross-sectional view of the window guide structure of FIG. 1;

[0015]FIG. 3 shows a motorized reducer;

[0016]FIG. 4 shows an alternate mounting process of a drum to a drive member;

[0017]FIG. 5 shows a cross-sectional view of the window guide structure provided with an alternate wedge; and

[0018]FIG. 6 shows a top view of the window guide structure of FIG. 5.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0019]FIG. 1 shows a window guide structure 1 of a vehicle door 27. The window guide structure 1 includes a guide frame 6 having a window guide slot 26 (shown in FIG. 2), such as a window run. A window 3 is mounted in sliding arrangement in the window guide slot 26. A cable 7 is fixed to the window 3 by fasteners 8, as known in the art. The cable 7 passes through six deflection pulleys 9 disposed on the window guide structure 1 to form a circuit, which is also known in the art.

[0020] A wedge 2 is positioned between the window guide structure 1 and a cable drum 4, securing and immobilizing the drum 4. The wedge 2 can also be positioned between the window guide structure I and an intermediate part that is disposed between the wedge 2 and the drum 4, such as a drum casing. Also, a supporting plate 21 of the drum 4 is also received in the wedge 2.

[0021] As shown in FIG. 2, an edge of the wedge 2 is received in the window guide slot 26 and secured in the window guide slot 26 either by friction or by elastic deformation. For example, the guide frame 6 can include an elastomer seal 10 that secures the wedge 2 by elastic deformation.

[0022] The wedge 2 fixes the drum 4 in the longitudinal direction and the vertical direction relative to the window 3 without the use of cable sheaths. The wedge 2 is removable, and can be withdrawn once the drum 4 is immobilized.

[0023] The cable 7 is wound onto the drum 4 either before or after the wedge 2 is positioned between the window guide structure 1 and the drum 4. When the cable 7 is tightened, the drum 4, by the supporting plate 21, applies a compressive force to the wedge 2, securing the wedge 2 between the guide frame 6 of the window guide structure 1 and the drum 4. Therefore, during assembly, the window guide structure 1 can be transported to a vehicle door assembly bay without displacement of the wedge 2 or the drum 4.

[0024] After positioning the wedge 2, the fixed drum 4 is correctly positioned for coupling to the drive member 5. The drive member 5 operates the drum 4 to drive the cable 7 to move the window 3 in the vehicle door 27. In this example, the drive member 5 is a motorized reducer, however it is to be understood that the drive member 5 can also be a crank-operated manual drive device. The coupling of the drive member 5 to the drum 4 can be done by any known means. In one example, the drive member 5 is a motorized reducer including a rotary-driven damper 11 as an output member. The damper 11 includes radial notches 12. Upon coupling of the drive member 5 to the drum 4, studs 13 of the drum 4 are received in the radial notches 12 of the damper 11. A driving torque can thus be transmitted from the drive member 5 to the drum 4 to drive the cable 7.

[0025] After coupling the drive member 5 to the drum 4, the drive member 5 is then at least partially fixed to an inner panel 17 of the vehicle door 27. In one example, as shown in FIG. 3, the casing of the drive member 5 includes bores 14, 16 and 18. Three screws pass through the bores 14, 16 and 18, fixing the drive member 5 to the inner panel 17. Seals can also be provided around the screws to ensure water-tightness between the dry zone and damp zone of the vehicle door 27.

[0026] After at least partially fixing the drive member 5 to the inner panel 17, the wedge 2 is removed from the window guide structure 1. By employing the method of the present invention, the vehicle door 27 is devoid of plastic sheaths between the drum 4 and the cable deflection pulleys 9.

[0027] The wedge 2 is bent or curved to dispose the drum 4 proximate to its final transverse position. The drum 4 is mounted for rotation within a casing that includes a drum housing 20 and the drum supporting plate 21. The drum supporting plate 21 forms a shoulder and secures the drum 4 in the drum housing 20. The drum supporting plate 21 has an elongated part 22 projecting radially outward relative to the drum housing 20. The elongated part 22 is received in a clamp 23 that secures the drum 4 relative to the wedge 2 in the longitudinal, vertical and transverse directions. Friction of the elongated part 22 in the clamp 23 also provides security. The wedge 2 further includes an elongated part 24 that contacts the drum housing 20 to provide improved immobilization of the drum 4. The wedge 2 can also be adapted to secure the drum 4 by tension in the cable 7.

[0028] In one example, the wedge 2 allows deflection of the drum 4 in a direction transverse to the vehicle door 27, allowing the operator to easily re-engage the drum 4 with the drive member 5 to affect their coupling. The wedge 2 is sufficiently flexible to allow rotation about the vertical axis of the end securing the drum 4 to achieve this adjustment.

[0029] Alternately, the window guide structure 1 is inserted in a trough formed between the inner panel 17 and an outer panel of the vehicle door 27. The window guide structure 1 is fixed to the panels by any suitable known means. If the drive member 5 is a motorized reducer, the drive member 5 is preferably fixed in the dry zone during coupling. The inner panel 17 and any other suitable element can ensure water tightness between the motor of the motorized reducer and the surroundings of the drum 4.

[0030] The wedge 2 allows the drum 4 to rotate. When the drive member 5 is rotated, drum 4 rotates to tighten the cable 7. The cable 7 is first positioned in the deflection pulleys 9 of the window guide structure 1. The wedge 2 is then positioned between the drum 4 and the guide frame 6, and the cable 7 is wound around the drum 4 to form the cable circuit. The drive member 5 is partially fixed to the inner panel 17 by pivotally mounting the drive member 5 about an axis staggered relative to the rotational axis of the drum 4. As could be appreciated from FIG. 3, the drive member 5 is partially fixed to the inner panel 17 by passing a screw through the bore 14, allowing the drive member 5 to pivot about this screw.

[0031] As shown in FIG. 4, when the drive member 5 is in position A, the bores 15 and 16 of the drive member 5 casing may be offset relative to the corresponding screw threads 18 and 19, respectively, in the inner panel 17. At this position, the tension in the cable 7 is low, facilitating the assembly of the vehicle door 27. By rotating the drive member 5 to position B, the tension in the cable 7 is increased. The bores 15 and 16 in the drive member 5 are aligned with the respective screw threads 18 and 19 of the inner panel 17. Screws are received in the aligned holes 15 and 16 and the respective screw threads 18 and 19, fixing the drive member 5 to the inner panel 17 and increasing the tension in the cable 7.

[0032] The above described wedge 2 is preferably removed after the drive member 5 is coupled to the drum 4. Alternately, as shown in FIGS. 5 and 6, the wedge 2 is not removed after the drive member 5 is coupled to the drum 4. The wedge 2 is secured to the guide frame 6 by studs fixed on the guide frame 6 or by screws 25 threaded into bores in the guide frame 6. Preferably, the wedge 2 is not rigidly fixed to the guide frame 6 so that the wedge 2 can slightly shift upon the assembly of the drive member 5, preventing squeezing of the studs or screws 25. As in the previous examples, the wedge 2 secures the drum 4 in a fixed position in the vertical and longitudinal directions, allowing an operator to correctly position drum 4 for coupling to the drive member 5. The wedge 2 can also be bent as in FIG. 1 or can allow deflection of the drum 4 in the transverse direction.

[0033] The wedge 2 of FIGS. 5 and 6 further includes an integrated drum housing 28. When the wedge 2 is fixed, the supporting plate 21 secures the drum 4 in the drum housing 28 of the wedge 2. The supporting plate 21 is secured to the drum housing 28 by attachment members 29. Alternately, the supporting plate 21 can be part of the wedge 2 and the housing 28 can be added, such as shown in FIGS. 1 and 2. These variants reduce the number of parts in the vehicle door 27.

[0034] Of course, the present invention is not limited to the examples and embodiments described and represented, but it is subject to numerous variants open to the person skilled in the art. As one example, although the placement of the wedge in a slot in the window guide frame has principally been described, the wedge can also be positioned between a belt-line mask and the drum.

[0035] The foregoing description is only exemplary of the principles of the invention. Many modifications and variations of the present invention are possible in light of the above teachings. The preferred embodiments of this invention have been disclosed, however, so that one of ordinary skill in the art would recognize that certain modifications would come within the scope of this invention. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. For that reason the following claims should be studied to determine the true scope and content of this invention. 

What is claimed is:
 1. A method of assembling a drive for a window to be mounted in a vehicle door comprising the steps of: providing a window guide and a drum that drives a cable; positioning a securing member between said window guide and said drum to secure said drum; and winding said cable onto said drum.
 2. The method as recited in claim 1, further including the steps of coupling a drive member to said drum and at least partially fixing said drive member to a vehicle door.
 3. The method as recited in claim 2, further comprising the step of removing said securing member after the step of at least partially fixing said drive member.
 4. The method as recited in claim 2, wherein said drive member is at least partially fixed to an inner panel of the vehicle door.
 5. The method as recited in claim 1, further comprising the steps of providing an inner panel and an outer panel of the vehicle door and inserting said window guide between said inner panel and an outer panel.
 6. The method as recited in claim 1, wherein said drum is secured in a vertical direction and a longitudinal direction by said securing member.
 7. The method as recited in claim 1, wherein said securing member allows deflection of said drum in a direction transverse to the plane of the vehicle door.
 8. The method as recited in claim 1, wherein said window guide includes a frame provided with a window guide slot, and the step of positioning said securing member includes inserting said securing member in said slot.
 9. The method as recited in claim 8, further including a seal in said window guide slot, and said securing member is positioned between said seal and said drum.
 10. The method as recited in claim 2, further comprising the steps of: placing said cable in at least one deflection pulley of the window guide prior to the steps of positioning said securing member and winding said cable; mounting said drive motor pivotally about an axis offset relative to a rotational axis of said drum during the step of at least partially fixing said drive member; tensioning said cable by pivoting said drive motor about said offset axis; and fixing said drive motor to said vehicle door after the step of tensioning said cable.
 11. The method as recited in claim 12, wherein said drive member is a motorized reducer.
 12. The method as recited in claim 1, wherein said securing member is a wedge.
 13. The method as recited in claim 2, wherein said drive member is at least partially fixed to said vehicle door by at least one screw.
 14. The method of claim 2, wherein the drive member is a motorized reducer, and said motorized reducer is fixed in a dry zone of the vehicle door.
 15. The method as recited in claim 1, further including the step of fixing said securing member to said window guide.
 16. The method as recited in claim 15, wherein said securing member forms a part of a drum housing.
 17. A method of assembling a vehicle door comprising the steps of: placing a cable in at least one deflection pulley of the window guide; providing a window guide and a drum that drives said cable; positioning a securing member between said window guide and said drum to secure said drum; winding said cable onto said drum; coupling a drive member to said drum; at least partially fixing said drive member to said vehicle door by mounting said drive motor pivotally about an axis offset relative to a rotational axis of a drum, tensioning said cable by pivoting said drive motor about said offset axis, and fixing said motorized reducer to said vehicle door after the step of tensioning said cable; and removing said securing member after the step of at least partially fixing said drive member.
 18. A pre-assembled window drive unit to be mounted to a vehicle door comprising: a window guide; a drum for driving a cable; and a securing member securing said window guide to said drum to secure said drum at a desired location.
 19. A pre-assembled unit as set forth in claim 18, wherein said window guide includes a frame and a window guide slot, and said securing member is received in said slot at one side, and secured drum at an opposed side.
 20. A pre-assembled unit as set forth in claim 18, wherein said securing member is fixed to said drum and to said window guide. 